Integrated process design, scheduling, and control using multiparametric programming

Markov decision process design: A framework for integrating strategic and operational decisions

We consider the problem of optimally designing a system for repeated use under uncertainty. We develop a modeling framework that integrates the design and operational phases, which are represented by a mixed-integer program and discounted-cost infinite-horizon Markov decision processes, respectively. We seek to simultaneously minimize the design costs and the subsequent expected operational costs. This problem setting arises naturally in several application areas, as we illustrate through examples. We derive a bilevel mixed-integer linear programming formulation for the problem and perform a computational study to demonstrate that realistic instances can be solved numerically.

Smart manufacturing inspired approach to research, development, and scale-up of electrified chemical manufacturing systems

As renewable electricity becomes cost competitive with fossil fuel energy sources and environmental concerns increase, the transition to electrified chemical and fuel synthesis pathways becomes increasingly desirable. However, electrochemical systems have traditionally taken many decades to reach commercial scales. Difficulty in scaling up electrochemical synthesis processes comes primarily from difficulty in decoupling and controlling simultaneously the effects of intrinsic kinetics and charge, heat, and mass transport within electrochemical reactors. Tackling this issue efficiently requires a shift in research from an approach based on small datasets, to one where digitalization enables rapid collection and interpretation of large, well-parameterized datasets, using artificial intelligence (AI) and multi-scale modeling. In this perspective, we present an emerging research approach that is inspired by smart manufacturing (SM), to accelerate research, development, and scale-up of electrified chemical manufacturing processes. The value of this approach is demonstrated by its application toward the development of CO₂ electrolyzers.

A systematic techno-economic approach to decide between continuous and batch operation modes for injectable manufacturing

A comprehensive approach is proposed to systematically determine the optimal mode of operation between continuous and batch injectable manufacturing considering product and market conditions. At the core of this approach are two integrated complete mathematical modules for discrete and continuous injectable manufacturing, which are supplemented with an economic evaluation module that can then be used to explore the impact of all relevant process parameters (e.g., lot-size, number of operators, solubility, product demand, raw material costs). When the developed approach was applied to two case studies, it was found that batch production was preferred at low to moderate solution (raw material) costs. In contrast, at higher solution costs, the preference for batch and continuous production processes changed back and forth as the annual product demand changed. The study also found that continuous production processes became increasingly preferred at medium to large final dosage volumes and a competitive alternative even at moderate solution costs. From a decision-making point of view, batch injectable manufacturing will be preferred over the novel continuous manufacturing technology unless there is a significant economic incentive to overcome the perceived technology risk. The proposed approach is intended as a decision-support tool for pharmaceutical process engineers.

Modelling for Digital Twins—Potential Role of Surrogate Models

The application of white box models in digital twins is often hindered by missing knowledge, uncertain information and computational difficulties. Our aim was to overview the difficulties and challenges regarding the modelling aspects of digital twin applications and to explore the fields where surrogate models can be utilised advantageously. In this sense, the paper discusses what types of surrogate models are suitable for different practical problems as well as introduces the appropriate techniques for building and using these models. A number of examples of digital twin applications from both continuous processes and discrete manufacturing are presented to underline the potentials of utilising surrogate models. The surrogate models and model-building methods are categorised according to the area of applications. The importance of keeping these models up to date through their whole model life cycle is also highlighted. An industrial case study is also presented to demonstrate the applicability of the concept.

Multiparametric Programming in Process Systems Engineering: Recent Developments and Path Forward

The inevitable presence of uncertain parameters in critical applications of process optimization can lead to undesirable or infeasible solutions. For this reason, optimization under parametric uncertainty was, and continues to be a core area of research within Process Systems Engineering. Multiparametric programming is a strategy that offers a holistic perspective for the solution of this class of mathematical programming problems. Specifically, multiparametric programming theory enables the derivation of the optimal solution as a function of the uncertain parameters, explicitly revealing the impact of uncertainty in optimal decision-making. By taking advantage of such a relationship, new breakthroughs in the solution of challenging formulations with uncertainty have been created. Apart from that, researchers have utilized multiparametric programming techniques to solve deterministic classes of problems, by treating specific elements of the optimization program as uncertain parameters. In the past years, there has been a significant number of publications in the literature involving multiparametric programming. The present review article covers recent theoretical, algorithmic, and application developments in multiparametric programming. Additionally, several areas for potential contributions in this field are discussed, highlighting the benefits of multiparametric programming in future research efforts.

Integrated Data-Driven Process Monitoring and Explicit Fault-Tolerant Multiparametric Control

We propose a novel active fault-tolerant control strategy that combines machine learning based process monitoring and explicit/multiparametric model predictive control (mp-MPC). The strategy features (i) data-driven fault detection and diagnosis models by using the support vector machine (SVM) algorithm, (ii) ranking via a nonlinear, kernel-dependent, SVM-based feature selection algorithm, (iii) data-driven regression models for fault magnitude estimation via the random forest algorithm, and (iv) a parametric optimization and control (PAROC) framework for the design of the explicit/multiparametric model predictive controller. The resulting explicit control strategies correspond to affine functions of the system states and the magnitude of the detected fault. A semibatch process, an example for penicillin production, is presented to demonstrate how the proposed framework ensures smart operation for which rapid switches between a priori computed explicit control action strategies are enabled by continuous process monitoring information.

Towards the Grand Unification of Process Design, Scheduling, and Control—Utopia or Reality?

As a founder of the Process Systems Engineering (PSE) discipline, Professor Roger W.H. Sargent had set ambitious goals for a systematic new generation of a process design paradigm based on optimization techniques with the consideration of future uncertainties and operational decisions. In this paper, we present a historical perspective on the milestones in model-based design optimization techniques and the developed tools to solve the resulting complex problems. We examine the progress spanning more than five decades, from the early flexibility analysis and optimal process design under uncertainty to more recent developments on the simultaneous consideration of process design, scheduling, and control. This formidable target towards the grand unification poses unique challenges due to multiple time scales and conflicting objectives. Here, we review the recent progress and propose future research directions.